Acoustics-based diagnostics

ABSTRACT

Described herein is a technology for facilitating diagnosis of the operation of devices or machines based, at least in part, upon the acoustics of such.

BACKGROUND

[0001] In the life of each machine with moving parts, the day comes whenparts wear or fail. When that day comes, someone must fix or replace theworn or failed parts. Otherwise, the useful life of that machine isover. The cause of the fault needs to be identified for the machine tocontinue its serviceable life.

[0002] This is true for wide range of devices and machines with movingparts and/or consumables. For example, it is true for engines, scanners,cranes, pencil sharpeners, trucks, ships, transmissions, vendingmachines, printers, jukeboxes, elevators, air conditioners, faxmachines, pumps, trains, photocopiers, and on and on.

Abnormal Operation

[0003] Herein, abnormal operation refers to the operation of a device ormachine that is not consistent with its regular, productive, and usefulfunctions. Particularly, these functions are those that are consistentwith effective performance. With the brakes of an automobile, forexample, the sound of metal grinding on metal probably indicates anabnormal operation. While the brakes are still operational andfunctional, their function is hampered. The noise indicates its abnormaloperation.

[0004] For simplicity, this discussion will focus on the abnormaloperation with office machinery. More particularly, it will focus on theprinters typically found in the office or home environments, such aslaser or ink-jet printers.

Troubleshooting Abnormal Printer Operation

[0005] A typical troubleshooting scenario for a printer includes acustomer calling a technical support center for help. The customerdescribes the issue to the technician over the telephone. It istechnician's goal to solve the problem; however, it is typical that sheonly has the information gleaned from the customer's observations andinterpretations.

[0006] For example, the customer may describe the condition as a “paperjam.” Frequently, the technician asks when the jam occurs during theprinter operation. Typically, the technician receives answers much likethis example: “it feeds a little ways and then it starts crinkling thepaper.” Therefore, the technician must rely on the customer'sobservations and interpretations of the printer operation.

[0007] Consequently, remote troubleshooting between the customer andtechnician may fail to find the cause of the trouble as efficiently oreffectively as desired. Therefore, an on-site troubleshooting visit maybe necessitated.

[0008] Since a field technician can directly observe the abnormalprinter operation, an on-site visit frequently results in extremelyefficient and quick solutions for the trouble. However, an on-site visitcan be quite costly compared to remote troubleshooting. On-site visitsinclude significant overhead, such as travel, labor-costs, training, andequipment.

[0009] There are significant drawbacks to this dual-tieredtroubleshooting approach (of remote and then on-site). Some of thosedrawbacks include:

[0010] cost of on-site visits;

[0011] cost of field and remote technicians;

[0012] cost of training field and remote technicians;

[0013] scarceness of trained field and remote technicians;

[0014] When under warranty, the manufacturer bears the burden of some orall of the time and expense of troubleshooting (including on-sitevisits). Even after the warranty expires, reducing the need fortroubleshooting (especially on-site visits) reduces overall operatingand overhead costs. It frees up resources for other tasks.

Some of the Drawbacks to Conventional Troubleshooting

[0015] With conventional troubleshooting, the remote techniciantypically relies on the observations and interpretations of a localuntrained observer. While less expensive than on-site visits,conventional remote troubleshooting is less effective and efficient(with regard to problem solving) than having an on-site expert (e.g., afield technician).

[0016] Furthermore, conventional troubleshooting relies on trainedpersonnel (e.g., remote and field technicians) to properly diagnoseabnormal operation of machines with moving parts (e.g., printers).

SUMMARY

[0017] Described herein is a technology for facilitating diagnosis ofthe operation of devices or machines based, at least in part, upon theacoustics of such.

[0018] One implementation, described herein, has a sound-gatheringsystem configured to gather sound produced by the operation of a deviceand it has a sound-analyzer configured to analyze the sound gathered bythe sound-gathering system and determine a fault-condition of thedevice. Furthermore, it has a fault-signature database interfaceconfigured to interface and acquire one or more fault-signaturesassociated with the device from a database of such. The analysis of thegathered sound by the sound-analyzer is based upon the one or morefault-signatures acquired from the database.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The same numbers are used throughout the drawings to referencelike elements and features.

[0020]FIG. 1 illustrates an environment and an architecture that is inaccordance with an implementation described herein.

[0021]FIG. 2 is a flow diagram showing a methodological implementationdescribed herein.

[0022]FIG. 3 is an example of a printer architecture capable ofimplementing an implementation (wholly or partially) described herein.

[0023]FIG. 4 is an example of a computing operating environment capableof implementing an implementation (wholly or partially) describedherein.

DETAILED DESCRIPTION

[0024] The following description sets forth one or more exemplaryimplementations of an acoustics-based diagnostics. The inventors intendthese exemplary implementations to be examples. The inventors do notintend these exemplary implementations to limit the scope of the claimedpresent invention. Rather, the inventors have contemplated that theclaimed present invention might also be embodied and implemented inother ways, in conjunction with other present or future technologies.

[0025] An example of an embodiment of an acoustics-based diagnostics maybe referred to as an “exemplary diagnostics.”

Introduction

[0026] For convenience and clarity of explanation, the bulk of thedescription herein focuses on office machinery and computer peripherals.Two common examples are printers and scanners. Therefore, the terms“office machinery”, “computer peripheral”, or “peripheral” expresslyincludes printers and scanners along with other devices that are notlisted, but are similar in nature.

[0027] However, unless the context clearly indicates otherwise, thediscussion herein applies to all devices and machines that producesounds—especially, when such sound represents an abnormal operatingcondition. Common office machines fit into this classification. Forexample, printers, scanners, computer peripherals, photocopiers,facsimile machines, computers, etc. Therefore, the term “office machine”expressly includes these devices listed here along with others that arenot listed, but are similar in nature.

[0028] By way of example only and not limitation, this is a list ofother such devices and machinery that fit into this classification ofthose that produce sounds—especially, when such sound represents anabnormal operating condition:

[0029] audio components;

[0030] electronics;

[0031] engines.

[0032] In addition, unless the context indicates otherwise, the term“sound,” as used herein, includes both audible and inaudible sounds. Inother words, “sounds” includes sounds that are audible to humans, andsounds that are below the human audible range (i.e., subsonic), andsounds that are above the human audible range (i.e., ultrasonic).

Brief Overview

[0033] The one or more exemplary implementations, described herein, ofthe present invention may be implemented (in whole or in part) byacoustics-based diagnosis architecture 100.

[0034] With the exemplary diagnostics, mechanical issues of anabnormally operating printer may be diagnosed based upon the sound ofthe abnormal operation. With a database of acoustic “fault signatures”for a printer, the exemplary diagnostics automatically troubleshoots anysound emitting abnormal operation. The exemplary diagnostics analyzesthe subject sound and compares it to the library of fault signatures.

[0035] Furthermore, this database may also include “fault-predictivesignatures.” With these, the exemplary diagnostics automaticallyidentifies an impending fault, which would cause the printer tooperateing abnormally. The fault has not happened yet, but the printeris emitting a telltale sound that indicates a failure is likely to occurin the near future. Consequently, preventive maintenance may beperformed more effectively and efficiently.

Exemplary Acoustics-based Diagnosis Architecture

[0036]FIG. 1 illustrates the acoustics-based diagnosis architecture 100,a diagnostic device 150, and an example of office machinery, namely aprinter 160. Using the acoustics-based diagnosis architecture 100, onemay automatically diagnose abnormal operation of a printer based uponthe sounds of such operation. In other words, it is based upon theacoustics of the abnormal operation.

[0037] The subject of the diagnostics is the printer 160. Of course, itemits sounds when operating. Item 170 indicates to sounds that it emitswhen operating abnormally.

[0038] Diagnostic device 150 is illustrated as a separate device in acircular, hockey-puck-like casing. It houses the components of theacoustics-based diagnosis architecture 100. This is an example of oneimplementation. However, the diagnostic device 150 may be most any othersized and shaped casing.

[0039] Furthermore, the diagnostic device 150 need not be separate fromthe printer 160. One or more of its components may be integrated intothe printer itself. Moreover, the communicatively linked components ofthe acoustics-based diagnosis architecture 100 may be separately housedin different devices.

[0040] The acoustics-based diagnosis architecture 100 includessound-gathering system 110 for gathering and amplifying sound 170.Sound-gathering system 110 typically includes a microphone 112 and anamplifier (not shown separately). The architecture 100 may also includean analog-to-digital (A/D) converter (not shown separately) to convertthe sound into a digital representation.

[0041] The microphone 112 of the sound-gathering system 110 may be amicrophone connected to a laptop computer of a field technician. It maybe located inside the printer itself.

[0042] The microphone may be mounted on or inside the front panel of theprinter and generates a signal, which is sent to a main processor. Thesignal may be amplified, digitized or otherwise processed before it isinputted to the main processor. The input signal is representative ofnoise coming from the printer internally. Having the microphonestrategically placed (e.g., near the gear mechanism) may make it easierto acquire the signal needed to diagnose problems.

[0043] Although the microphone 112 of the sound-gathering system 110will be located within hearing distance of the subject printer 160,nearly all of the other components of the acoustics-based diagnosisarchitecture 100 may be located remotely from the printer.

[0044]FIG. 1 shows the acoustics-based diagnosis architecture 100further includes a sound-analyzer 114 and fault-signature database 118.

[0045] The sound-analyzer 114 analyzes the sampled sound from theprinter's abnormal operation. Typically, the sound-analyzer will includea computer and one or more program modules. It may also be a dedicatedhardware device. As part of that analysis, it may access the database118 of “fault signatures” or “fault fingerprints.”

[0046] Within the acoustics-based diagnosis architecture 100, thesound-analyzer 114 processes the input signal from the sound gatheringsystem 110 as by using zero-crossing time-sliced FFT (Fast FourierTransform) at predetermined intervals to analyze printer noise. Forexample, it might use 100 msec time slices. The fingerprint of a noisepattern from database 118 is sent to analyzer 114 which may be, forexample, a printer driver software module (running on a connectedpersonal computer). Alternatively, it maybe analyzed by a hardwiredcircuitry on the printer itself.

[0047] In one implementation, the sound-analyzer 114 is part of aprocessor board of the printer 160 and the “fault signatures” are storedon a database 118, which is a network-connected server, such as a webserver.

[0048] If the acoustics-based diagnosis architecture 100 is near or partof the printer, it can very effectively “listen” to the printer'soperation and determine whether there are any abnormal sounds that couldsignal an existing or an impending problem.

[0049] In another implementation, the sound-analyzer 114 and the memory116 are part of a separate computer that is communicatively connected tothe printer 160. The computer may be running a special program moduleand/or printer driver. In this implementation, the database of “faultsignatures” is stored on the computer or on a network-connected server,such as a web server.

[0050] All of the components of the acoustics-based diagnosisarchitecture 100 may be connected via local or remote communicationslinks (wired or wireless). Therefore, they need not be collectedtogether within a singular device.

[0051] In addition, these components do not need to be dedicated to thisfunctionality. The components may be shared with other devices andfunctionalities. For example, the sound-analyzer may be same centralprocessor used by the printer itself; a CPU of a general-purposepersonal computer; a processor of a web server, etc.

[0052] The database 118 may be, for example, contained in a device, suchas the device 150, and that device may contain other components of theacoustics-based diagnosis architecture 100 as well. The database 118 mayalso be stored on a computer storage medium (like the hard drive of alaptop); stored on a remotely linked web server; etc.

Predictive Preventive Maintenance

[0053] In addition to diagnosing present abnormal operating conditionsof the printer, the exemplary diagnostics may predict the onset of anabnormal condition in the near future. While the printer appears to beoperating normally, it may emit telltale sounds that indicate a need formaintenance or repair in the near future. For example, a small squeakfrom a gear may indicate that it will need replacement within two-threemonths.

[0054] With the exemplary diagnostics, preventive maintenance may beeffectively performed from the failure prediction based upon the soundsthe printer is emitting. This will help reduce downtime by allowing userto schedule maintenance on issues before they occur.

Database

[0055] Each problem condition (“fault”) will typically have a uniqueaudio signature (“fault signature”). Each predictive problem conditionwill also typically have its own unique audio signature (“predictivefault signature”). These fault signatures can be determined empiricallyand with a dose of heuristics. In other words, a series of numerousexperiments (or field tests) are performed on each subject device torecord the sounds of various fault and predictive-fault conditions. Theautomatic troubleshooting using these fault signatures may be refinedbased upon the experience and knowledge of expert technicians

[0056] Such fault signatures may be categorized and associated in arelational database. Diagnostic algorithms compare noise signals to oneor more fault signatures to draw conclusions regarding the existence ofone or more current or future problem condition(s).

Time Delayed Analysis of Abnormal Operational Sounds

[0057] In another implementation of the exemplary diagnostics, thesounds of the printer may be recorded. That recording may be stored. Itmay be transmitted or delivered to a sound processing center.

[0058] With this implementation, the operational sounds of the printerare manually or automatically recorded (e.g., MP3 format). This soundfile may be processed by a computer linked to the printer.Alternatively, this sound file may be transmitted (e.g., via email) to aremote sound processing center.

Methodological Implementation of the Exemplary Diagnostics

[0059]FIG. 2 shows a methodological implementation of the exemplarydiagnostics performed by the acoustics-based diagnosis architecture 100(or some portion thereof). This methodological implementation may beperformed in software, hardware, or a combination thereof.

[0060] At 210 of FIG. 2, the exemplary diagnostics obtains sound emittedby a subject device. Herein, the primary example of a subject device isa printer, but it may be any devices or machine that producessounds—especially, when such sound represents an abnormal operatingcondition. The sound-gathering system 110 is the primary example ofcomponent that the acoustics-based diagnosis architecture 100 may employto accomplish this.

[0061] At 212, the input sound is processed. It may be processedimmediately upon receiving it or at a later time (if the sound had beenrecorded). The sound-analyzer 114 is the primary example of a componentthat the acoustics-based diagnosis architecture 100 may employ toaccomplish this.

[0062] Other examples are A/D converters, amplifiers, filters, etc,which may be used in combination with a primary processor. Thisprocessing step places the sound signal in a form suitable for analysis.

[0063] At 214, the exemplary diagnostics accesses data in afault-signature database. This database may include fault-signatures ofboth current faults and predictive faults. The database 118 is theprimary example of component that the acoustics-based diagnosisarchitecture 100 may employed to store the signatures.

[0064] At 216, the exemplary diagnostics analyzes the input soundcomparing it to one or more fault signatures acquired from the database.Based upon such analysis, it determines whether a current faultcondition exists and what that condition is. At 218, it indicates theresult of that determination.

[0065] The exemplary diagnostics may optionally determine whether afuture fault condition exists and what that condition is. At 220, itindicates the result of that determination.

[0066] The process ends at 222.

Exemplary Printer Architecture

[0067]FIG. 3 illustrates various components of an exemplary printingdevice 300 that can be utilized the exemplary diagnostics.

[0068] Printer 300 includes one or more processors 302, an electricallyerasable programmable read-only memory (EEPROM) 304, ROM 306(non-erasable), and a random access memory (RAM) 308. Although printer300 is illustrated having an EEPROM 304 and ROM 306, a particularprinter may only include one of the memory components. Additionally,although not shown, a system bus typically connects the variouscomponents within the printing device 300.

[0069] The printer 300 also has a firmware component 310 that isimplemented as a permanent memory module stored on ROM 306. The firmware310 is programmed and tested like software, and is distributed with theprinter 300. The firmware 310 can be implemented to coordinateoperations of the hardware within printer 300 and contains programmingconstructs used to perform such operations.

[0070] Processor(s) 302 process various instructions to control theoperation of the printer 300 and to communicate with other electronicand computing devices. The memory components, EEPROM 304, ROM 306, andRAM 308, store various information and/or data such as configurationinformation, fonts, templates, data being printed, and menu structureinformation. Although not shown, a particular printer can also include aflash memory device in place of or in addition to EEPROM 304 and ROM306.

[0071] Printer 300 also includes a disk drive 312, a network interface314, and a serial/parallel interface 316. Disk drive 312 providesadditional storage for data being printed or other informationmaintained by the printer 300. Although printer 300 is illustratedhaving both RAM 308 and a disk drive 312, a particular printer mayinclude either RAM 308 or disk drive 312, depending on the storage needsof the printer. For example, an inexpensive printer may include a smallamount of RAM 308 and no disk drive 312, thereby reducing themanufacturing cost of the printer.

[0072] Network interface 314 provides a connection between printer 300and a data communication network. The network interface 314 allowsdevices coupled to a common data communication network to send printjobs, menu data, and other information to printer 300 via the network.Similarly, serial/parallel interface 316 provides a data communicationpath directly between printer 300 and another electronic or computingdevice. Although printer 300 is illustrated having a network interface314 and serial/parallel interface 316, a particular printer may onlyinclude one interface component.

[0073] Printer 300 also includes a print unit 318 that includesmechanisms arranged to selectively apply ink (e.g., liquid ink, toner,etc.) to a print media such as paper, plastic, fabric, and the like inaccordance with print data corresponding to a print job. For example,print unit 318 can include a conventional laser printing mechanism thatselectively causes toner to be applied to an intermediate surface of adrum or belt. The intermediate surface can then be brought within closeproximity of a print media in a manner that causes the toner to betransferred to the print media in a controlled fashion. The toner on theprint media can then be more permanently fixed to the print media, forexample, by selectively applying thermal energy to the toner.

[0074] Print unit 318 can also be configured to support duplex printing,for example, by selectively flipping or turning the print media asrequired to print on both sides. Those skilled in the art will recognizethat there are many different types of print units available, and thatfor the purposes of the present invention, print unit 318 can includeany of these different types.

[0075] Printer 300 also includes a user interface and menu browser 320,and a display panel 322. The user interface and menu browser 320 allowsa user of the printer 300 to navigate the printer's menu structure. Userinterface 320 can be indicators or a series of buttons, switches, orother selectable controls that are manipulated by a user of the printer.Display panel 322 is a graphical display that provides informationregarding the status of the printer 300 and the current optionsavailable to a user through the menu structure.

[0076] Printer 300 can, and typically does, include applicationcomponents 324 that provide a runtime environment in which softwareapplications or applets can run or execute. One exemplary runtimeenvironment is a Java Virtual Machine (JVM). Those skilled in the artwill recognize that there are many different types of runtimeenvironments available. A runtime environment facilitates theextensibility of printer 300 by allowing various interfaces to bedefined that, in turn, allow the application components 324 to interactwith the printer.

Exemplary Computer Architecture

[0077]FIG. 4 illustrates various components of an exemplary computingdevice 400 that can be utilized to implement the exemplary diagnostics.

[0078] Computer 400 includes one or more processors 402, interfaces 404for inputting and outputting data, and user input devices 406.Processor(s) 402 process various instructions to control the operationof computer 400, while interfaces 404 provide a mechanism for computer400 to communicate with other electronic and computing devices. Userinput devices 406 include a keyboard, mouse, pointing device, or othermechanisms for interacting with, and inputting information to computer400.

[0079] Computer 400 also includes a memory 408 (such as ROM and/or RAM),a disk drive 410, a floppy disk drive 412, and a CD-ROM drive 414.Memory 408, disk drive 410, floppy disk drive 412, and CD-ROM drive 414provide data storage mechanisms for computer 400. Although not shown, asystem bus typically connects the various components within thecomputing device 400.

1. A method for acoustics-based diagnosis, the method comprising:obtaining a sound emitted by a device; processing the sound; acquiringone or more acoustics-based fault-signatures associated with the device;analyzing the processed sound based upon the one or more acquiredfault-signatures; based upon such analysis, determining whether thedevice has a fault condition evidenced by the sound that it emitted;indicating the result of such determination.
 2. A method as recited inclaim 1, wherein the fault condition is a present fault condition.
 3. Amethod as recited in claim 1, wherein the fault condition is a futurefault condition.
 4. A method as recited in claim 1, wherein the deviceis office machinery.
 5. A method as recited in claim 1, wherein thedevice is selected from a group consisting of: computer peripheral;printer; scanner; fax machine; electronics.
 6. A computer-readablemedium having computer-executable instructions that, when executed by acomputer, performs a method for acoustics-based diagnosis, the methodcomprising: obtaining a sound emitted by a device; processing the sound;acquiring one or more acoustics-based fault-signatures associated withthe device; analyzing the processed sound based upon the one or moreacquired fault-signatures; based upon such analysis, determining whetherthe device has a fault condition evidenced by the sound that it emitted;indicating the result of such determination.
 7. A medium as recited inclaim 6, wherein the fault condition is a present fault condition.
 8. Amedium as recited in claim 6, wherein the fault condition is a futurefault condition.
 9. A medium as recited in claim 6, wherein the soundsproduced by the device are indicative of one or more present abnormaloperating conditions.
 10. A medium as recited in claim 6, wherein thesounds produced by the device are indicative of one or more futureabnormal operating conditions.
 11. A method as recited in claim 6,wherein the device is selected from a group consisting of: officemachinery; copier; computer peripheral; printer; scanner; fax machine;electronics.
 12. A method for acoustics-based diagnosis, the methodcomprising: processing the sound emitted by a device; analyzing theprocessed sound based upon the one or more fault-signatures associatedwith the device; based upon such analysis, determining whether thedevice has a fault condition evidenced by the sound that it emitted. 13.A method as recited in claim 12 further comprising acquiring one or moreacoustics-based fault-signatures associated with the device.
 14. Amethod as recited in claim 12 further comprising indicating the resultof such determination.
 15. A method as recited in claim 12, wherein thefault condition is a present fault condition.
 16. A method as recited inclaim 12, wherein the fault condition is a future fault condition.
 17. Amethod as recited in claim 12, wherein the device produces sounds whenoperating under normal conditions.
 18. A method as recited in claim 12,wherein the device produces sounds when operating abnormally.
 19. Amethod as recited in claim 12, wherein the sounds produced by the deviceare indicative of one or more present abnormal operating conditions. 20.A method as recited in claim 12, wherein the sounds produced by thedevice are indicative of one or more future abnormal operatingconditions.
 21. A method as recited in claim 12, wherein the device isoffice machinery.
 22. A computer-readable medium havingcomputer-executable instructions that, when executed by a computer,performs a method for acoustics-based diagnosis, the method comprising:processing the sound emitted by a device; analyzing the processed soundbased upon one or more fault-signatures associated with the device;based upon such analysis, determining whether the device has a faultcondition evidenced by the sound that it emitted.
 23. A medium asrecited in claim 22, wherein the method further comprises acquiring oneor more acoustics-based fault-signatures associated with the device. 24.A medium as recited in claim 22, wherein the method further comprisesindicating the result of such determination.
 25. A medium as recited inclaim 22, wherein the fault condition is a present fault condition. 26.A medium as recited in claim 22, wherein the fault condition is a futurefault condition.
 27. An acoustics-based diagnostics architecturecomprising: a sound-gathering system configured to gather sound producedby the operation of a device; a sound-analyzer configured to analyze thesound gathered by the sound-gathering system and determine afault-condition of the device; a fault-signature database interfaceconfigured to interface and acquire one or more fault-signaturesassociated with the device from a database of such; wherein the analysisof the gathered sound by the sound-analyzer is based upon the one ormore fault-signatures acquired from the database.
 28. A system asrecited in claim 27, further comprising a fault-indicator configured toproduce an indication that specifies whether the device has a faultcondition evidenced by the sound that it produces.
 29. A system asrecited in claim 27, wherein the fault condition is a present faultcondition.
 30. A system as recited in claim 27, wherein the faultcondition is a future fault condition.
 31. A system for acoustics-baseddiagnostics, the system comprising: a memory comprising a set ofcomputer program instructions; and a processor coupled to the memory,the processor being configured to execute the computer programinstructions, which comprise: processing the sound emitted by a device;analyzing the processed sound based upon one or more fault-signaturesassociated with the device; based upon such analysis, determiningwhether the device has a fault condition evidenced by the sound that itemitted.
 32. A system as recited in claim 31, wherein the instructionsfurther comprise acquiring one or more acoustics-based fault-signaturesassociated with the device.
 33. A system as recited in claim 31, whereinthe instructions further comprise indicating the result of suchdetermination.
 34. A system as recited in claim 31, wherein the faultcondition is a present fault condition.
 35. A system as recited in claim31, wherein the fault condition is a future fault condition.
 36. Asystem as recited in claim 31, wherein the system is a printer.
 37. Aprinter comprising: a microphone; a memory comprising acoustic faultsignatures; a processor connected to receive a printer noise signalgenerated by the microphone and an acoustic fault signature signal fromthe memory.
 38. A printer as recited in claim 37, wherein the processoris configured to compare the printer noise signal to said acoustic faultsignature signal and generate a signal indicative of the comparison.